IMPORTANT. Failure to follow these instructions, incorrect use of the turbocharger or changes to it, may cause damage to the turbocharger as well as the engine and the consequent loss of the warranty. Most turbo breakdowns are caused by causes beyond its control. Taking these instructions into account is vital for its proper functioning as well as extending the life of the turbocharger. Remember that the warranty only covers the replacement or repair of the turbo and never the costs of its assembly or cranes, or other expenses that may be incurred.
Before carrying out the assembly, you must know the causes of the failure. So that the problem does not arise again, it will be checked if it has been caused by the malfunction of other components.
Each turbocharger is designed to match a specific engine and is given an individual part number and serial number. This is shown in the engine manufacturer's specification lists and on the turbocharger data plate.
If there is damage to the turbine rotor, examine the exhaust manifold to ensure that no foreign objects remain there or that the exhaust manifold is not disintegrating. Be thorough, even very small parts can cause serious damage to the rotor.
Check intake valves, heaters and intake parts that may have broken and entered the engine; these debris, when expelled from the exhaust manifold, seriously damage the turbo rotor.
If the bearings have excessive play, it may be due to lack, poor condition or low quality of the lubricating oil used, oil and filter must be changed. It is important that you always use top quality oil and filters. Replace the turbo oil inlet hose to ensure proper lubrication.
If there are oil leaks from the exhaust and intake sides, check all the crankcase breathers and valve cover, clean the accumulator/oil separator and check that there are no pressures in the crankcase that would make it difficult to drop.
Oil buildup in the intercooler can cause the engine to rev, clean it properly. Check that there are no foreign bodies or oil left in it.
If there is damage to the compressor rotor, check the filtration system and ductwork for unfiltered air and foreign objects. Be extremely careful when changing the air filter as any introduced object will end up hitting the compressor rotor, causing serious damage. Check the hoses, checking that there are no pinches in them, replacing them if necessary.
Thoroughly check the absence of foreign bodies in the outlet, cylinder head cover, oil vapor re-suction circuit, EGR valves and their ducts, clean by suction and, if necessary, pass a magnet through curves and valve.
Check that the engine and intercooler intake/exhaust systems are clean and free of obstructions. Replace the air filter if necessary.
Check that the oil intake and drain flanges are clean and free of obstructions (removing them to clean them if necessary). If in doubt, replace them with new ones. ATTENTION: Never use any type of sealant for joints.
Replace the oil and filter, ensuring that only recommended OEM parts and the specified oil are used.
Check that the exhaust mounting flange and studs are in good condition (no cracks or dirt). If in doubt, replace them with new ones. Next fit the turbocharger to the exhaust flange, checking that the turbine intake gasket fits correctly to provide a vacuum seal.
Connect the oil drain pipe and then fill the turbocharger oil feed hole with clean engine oil and slowly turn the rotor by hand. Connect all external connections to the turbocharger. Remove the fuel cap and crank the engine to obtain oil pressure.
Before starting the engine, give it a spin so that oil flows into the turbo. This can be done by disconnecting the injector connectors, turning the engine without starting and verifying that oil is reaching the turbo. We can disconnect the drain pipe from the turbo to the crankcase and observe that the oil flows without interruptions and normally. Once checked, tighten the turbo to crankcase drain tube again.
Start the engine and idle it, checking that all air, gas and oil connections are tight and leak-free, tightening any connections as necessary and using soapy water to help detect gas leaks.
Check that the engine compression is correct, poor compression will cause oil leaks from the turbocharger.
Do not give sudden acceleration and wait for the engine temperatures to stabilize, especially the oil temperature, before applying the maximum load, as well as waiting at idle for one minute before stopping the vehicle after carrying out long works with it.
What is good for turbochargers
The turbocharger is designed to last as long as the engine. It does not require any special maintenance, and inspection is limited to a small number of periodic checks.
To guarantee the life of the turbocharger, the engine manufacturer's service instructions must be observed:
- Oil change intervals
- Oil and air filter maintenance
- Oil pressure control
- Wait for the oil temperature to stabilize before putting the engine at full load.
What is bad for turbochargers
90% of all turbocharger failures are due to the following causes:
- Penetration of foreign bodies into the turbine or compressor.
- Dirt in the oil.
- Inadequate oil supply (oil pressure/filter system).
- Excessive exhaust gas temperature (starting system/injection system).
These failures can be avoided with regular maintenance. When performing maintenance on the air filter system, for example, care must be taken not to leave fragments of material that could enter the interior of the turbocharger.
Diagnosis
If the engine does not run correctly, it should not be assumed that the turbocharger is the cause of the failure.
Check that the engine compression is correct.
It often happens that turbochargers in good condition are replaced when the failure could be located in the engine.
Only after the previous points have been checked can the fault in the turbocharger be established.
We recommend that turbochargers be inspected only by qualified specialists.
Strange objects
- Ingestion of a foreign object through the intake duct, either through the air filter or the valve cover filter, hitting the compressor wheel and unbalancing the rotor or cartridge assembly.
- Ingestion of a foreign object through the exhaust gas inlet manifold duct, hitting the turbine shaft and the variable geometry, unbalancing the rotor assembly and slowing down the movement of the geometry cam.
Lack of lubrication
Breakage due to turbo fatigue or transfer of materials caused by the friction of one metal against another and the high temperatures derived from the low oil supply, the incorrect position of the gasket and the use of liquid gaskets or poor quality lubricants.
Oil contamination
Damage to the turbo support system usually occurs when there are too many carbon particles in suspension in the oil, because oil and filter changes have been spaced too far apart, or because maintenance is poor. Damage to the support system is also caused by metal particles from engine wear or steel fragments suspended in the oil after a major engine overhaul.
Turbine overspeed or excessive temperatureDamage to the turbo due to operation above the limits for which it was designed or the vehicle manufacturer's specifications. Maintenance issues, engine malfunctions, or unauthorized performance upgrades can cause the turbo to spin over its limits, causing fatigue failure of the compressor and turbine wheels.